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Specialty chemicals giant enhances 'Ex' inspections and cuts costs with pioneering data capture system

18 December 2012

Specialty chemicals manufacturer Innospec Inc, the world’s largest dedicated producer of fuel additives and a manufacturer of octane additives and active chemicals, has achieved an 85% reduction in inspection and repair hours for hazardous area inspections after adopting class leading data capture software from Terringtn Data Management.

Innospec reduced the annual cost of its Ex Inspections through the use of mobile computing and IndEx software. IndEx is an innovative data capture and inspection software package that enables the company to manage its asset register and regulatory equipment regime far more efficiently than the paper based methods previously used.

Innospec has circa 7,000 items to inspect on a 3 year cycle at its plant at Ellesmere Port in Cheshire.  Items include lights, motors, valves and transmitters and a 10% detailed “strip down” inspection is carried out annually to comply with the standards monitored by the Health and Safety Executive.

The company previously managed the inspection regime with a site plan, pen and paper with inspection reports being typed up at a later date and a return visit needed to rectify any defects.

Site Electrical Engineer, Paul Mills, says: “The IndEx software, coupled with the use of intrinsically safe hand held devices pre-loaded with details of the items to be inspected, clearly offers a faster, more accurate and cost-effective approach than the paper based method previously in use. Controls within IndEx safeguard data integrity whilst providing a full audit trail.  Process improvement efficiencies gained from using IndEx have enabled us to streamline our Ex inspection regime, resulting in an 85% reduction in inspection and repair hours.  This represents a significant annual saving and provides a substantial return on our investment that is much appreciated in the current economic climate.

“Using IndEx has enabled us to streamline the entire inspection and fault repair process. As the inspector tours the site the hand held prompts them on items to be inspected and the relevant checks required in line with IEC 60079-17. Engineers can carry out and record details of repairs at the time the fault is found which is a real cost saving benefit for us. On return to the office, the recorded information is downloaded to the database to provide a record of inspections carried out with a fully traceable record of when the inspection was made and who carried it out. IndEx is also really easy to use, even for people without much IT experience.’’

Paul Mills goes on to say: “IndEx provides immediate visibility of our asset register and the inspection history of each asset, along with full audit trails that help us to demonstrate that we are complying with legislation. A further benefit is that our asset register quickly provides access to asset status and location details, vital information in case of product recalls and safety notices as it helps us to locate equipment quickly and effectively.

“The IndEx database also carries all the certificates and details of the standard each item must be inspected to which saves inspectors having to go through paper files to locate them.” 

Terrington Data Management business development manager, Tracey Marshall, says: “IndEx stores detailed, auditable records help users prove that they are maintaining their site in a safe and efficient manner and in accordance with applicable regulations. IndEx is faster, offers greater accuracy and provides the scope for significant cost savings through better resource management.”

For further details on Terrington Data Management or its products, please contact business development manager, Tracey Marshall, Tel: +44 (0)1904 567674 or email tracey.marshall@terringtondm.com.


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